Where all your Profits vanish

There is a factory hidden inside your factory
Practically 40-50% of all your available and paid for Assets (Employees, Floor space, Inventory, Machines, Time, Opportunity) remain non-productive and underutilized.
The Hidden factory is where the largest amount of money, time, and resources are spent, and they are considered “waste”
The monies spend in the hidden factory has the greatest negative impact on the competitiveness and profitably of your organization. The TRUE “Cost of the Hidden Factory” is usually underestimated in most companies.
We have enough case studies and empirical date to showcase that this works up to anything between 12-22% of your Topline.
30% – 40% or more Capacity could be hiding in your Facility. Unbelievable but True.
We regularly discover 30% or more plant layout efficiencies facility owners never suspected. Our recommendations improve capacity and boost production for greater profitability.
Everything that occupies space in your facility but doesn’t create products – limits your profitability. We’ll show you how to produce more in less time – using the resources you already have under one roof.
As a plant owner your Goal is to:
Maximize the space/assets you’re in for the best value.
Increase capacity with new efficiencies
Get the most out of a new/existing space and assets.

What’s the best time for Lean layout Optimization

  • When you’re relocating your production to a new location.
  • When you’re starting to consider a new facility
  • When you’re running up against capacity constraints in your current location
  • When you need to expand your facility to accommodate growing operations.

Why hire a Lean Layout Consultant?

An independent, objective viewpoint can make all the difference. Our consultants can uncover production facility layout efficiencies you’d probably never think of. The benefits of hiring our team extend beyond fresh perspective, skilled eye and wealth of production design experience.

How do we uncover Plant efficiencies and help you see your plant in a New Light?

The basis of any facility design is rooted in the principles of Lean Manufacturing which enable organizations to:
  • Respond to customer requirements at a faster rate.
  • Reduce waste from Process and Operation
  • Minimize distances between operations and reduce costly transport.
  • Shorten production lead times
  • Saves space and removes clutter of excess WIP inventory.
  • Dramatically improve machines and asset utilization.
Our methodologies include but are not limited to:
  • Value Stream Mapping – Flow chart which identifies value and non-value-added activities within your operations.
  • Balanced Production – Improving productivity by providing optimal flow and balance through various manufacturing areas
  • Changeover – Process from converting a production line from one process to another.
  • Single-Piece Flow and Work – Reduce WiP and Eliminate wasteful exercises during production
  • Levelled Production – Systemically controlled productivity and steady production flow to improve on-time delivery and efficiency.
  • Inventory Management and Kanban – Systems to control the logistics of inventory.
Whether you’re relocating your facility or feel the need to expand, don’t make a move until you call our Lean layout consultants. Save valuable time, energy and money.
We are the industry expert in providing Business site relocation; Comprehensive Lean assessment; Equipment purchase and negotiations; Lean Manufacturing facility planning; Project feasibility; Detailed Project report; World class Manufacturing.
What opportunities are waiting to be uncovered under your roof?
Let’s have a discovery session and start envisioning the possibilities. to achieve greatest co-ordination and efficiency of 4 M’s (Men, Materials, Machines, and Methods) in a plant.
To learn more contact us at +919650733993 or send email to
Lean regards
The Idea Smith
Nimish Dave

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